US3487627A - Yarns of polymeric material - Google Patents

Yarns of polymeric material Download PDF

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Publication number
US3487627A
US3487627A US461617A US46161765A US3487627A US 3487627 A US3487627 A US 3487627A US 461617 A US461617 A US 461617A US 46161765 A US46161765 A US 46161765A US 3487627 A US3487627 A US 3487627A
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Prior art keywords
godet
yarn
filament
sleeve
filaments
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US461617A
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English (en)
Inventor
Cyril G Cannon
Barrie L Davies
Roy A Wililams
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British Nylon Spinners Ltd
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British Nylon Spinners Ltd
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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H54/00—Winding, coiling, or depositing filamentary material
    • B65H54/02—Winding and traversing material on to reels, bobbins, tubes, or like package cores or formers
    • B65H54/28—Traversing devices; Package-shaping arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H54/00—Winding, coiling, or depositing filamentary material
    • B65H54/02—Winding and traversing material on to reels, bobbins, tubes, or like package cores or formers
    • B65H54/28—Traversing devices; Package-shaping arrangements
    • B65H54/2833—Traversing devices driven by electromagnetic means
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/30—Handled filamentary material
    • B65H2701/31—Textiles threads or artificial strands of filaments

Definitions

  • This invention relates to yarns containing one or more continuous filaments of an artificial polymeric material, and to a process and apparatus used for making such yarn.
  • Filaments of an artificial polymeric material are most conveniently manufactured in the form of continuous-filaments, by wet, dry or melt-spinning processes.
  • These continuous filaments as conventionally made, are essentially straight with a marked regularity.
  • these qualities facilitate the close packing of adjacent filaments so that the yarn is a relatively dense and compact structure. This compactness is reflected in several undesirable properties manifest by such continuous filament yarns, for instance, a poor covering power, poor heat insulation, a low degree of bulkiness and a somewhat cold handle, and these detract from the recognised excellent strength.
  • modified continuous filamentyarns are typically made by processes which involve treating a filamentary bundle to crimp, loop or otherwise disperse, individual filaments therein and they are not ordinarily prepared in an operation fully integrated with the extrusion and making of the constituent continuous filaments.
  • This invention is directed to novel continuous filament yarns which are made from one or more continuous filaments in an operation which is fully integrated with the extrusion and formation of the constituent continuous filament or filaments.
  • the present invention has for one of its objects the provision of novel continuous filament yarns which simulate in certain respects notably in their bulk and covering power a staple fibre yarn spun from comparable fibres and containing an approximately equivalent number of fibres in their cross-section.
  • the present invention has for another of its objects the provision of a process for making novel continuous filament yarns by collecting one or more freshly extruded continuous filaments and assembling them directly into a yarn.
  • Another object of the present invention is to provide suitable apparatus for practicing the above process.
  • a continuous filament yarn which comprises a multiplicity of interconnected segments extending in a generally axial direction with a progressive advancement of segments along the axis, and with a majority of the segments contained for at least part of their length with another segment, said segments being twisted into a stable structure.
  • predicled bights emerge from the axiallyextending segments and extend outwardly therefrom.
  • the pedicled bights are not numerous in relation to the axially-extending segments and they are wrapped loosely around the segments to form a generally discontinuous binding of helically twisted loops along the segments.
  • the pedicled bights are numerous and they extend outwardly from the axiallyextending segments along their length in a more or less random array.
  • a yarn in which this arrangement is present comprises a distinct relatively compact core and a less compact peripheral region.
  • the core is formed of a multiplicity of the interconnected segments extending in a generally axial direction with a progressive advancement of segments along said axis, and with a majority of the segments contained for at least part of their length within another segment.
  • peripheral region in such a yarn is constituted by the pedicled bights which emerge from the core and extend outwardly therefrom in a random array. 1
  • the twist which imyarn is predominantly contained in the core.
  • the present invention further provides a process for making a yarn which comprises forming a continuous filament by the extrusion of a polymeric material, passing the continuous filament so formed to a rotating body around which the filament is wrapped, and having a peripheral speed which is sufficient to apply tension to, and to attenuate the continuous filament being passed thereto, imparting to the filament in the course of its passage to the body a reciprocating movement whereby the filament is assembled around the body in the form of a sleeve, continuously withdrawing the sleeve from the body in the direction of its axis of rotation and at a speed less than the peripheral speed of the body so as to insert twist, and collecting the yarns so obtained in an orderly manner.
  • the present invention also provides an apparatus for making a yarn which comprises means for extruding a polymeric material into one or more continuous filaments, a traverse mechanism located some distance away from the extrusion means and arranged to impart a reciprocating movement to the filament, a body arranged to rotate with a peripheral speed sufiiciently high to apply tension to the filament and to assemble the filament around it in the form of a sleeve, and means for withdrawing the sleeve at a slower speed than the peripheral speed of the rotatable body and for collecting the yarn so obtained.
  • continuous filaments as used herein and in the claiming clauses hereof refers to filaments which are of an indefinite length and which in the practise of the process of this invention are continuously supplied by extrusion from a source of the polymeric material.
  • the term does not include short length fibres, commonly referred to as staple fibres.
  • continuous filaments are extruded through the orifices in a spinneret from a source of the polymeric material and one or more of the continuous filaments are passed along a generally defined path, most usually downwards, until they have substantially completely solidified, when they are lead through a traverse mechanism and then onto the rotating body around which the filaments are wrapped in the form of a sleeve comprising a number of overlaid and interconnected helices.
  • the sleeve whilst it is continuously propagated by the filaments being passed to the rotating body, is also continuously pulled off the body in a progressive and controlled manner, so that the sleeve can be regarded as a transient assembly of wrapped filaments.
  • the rotating body may have a variety of shapes although it is preferred that it should be profiled so as to taper in the direction in which the sleeve is moved thereg of, for this facilitates the withdrawal of the sleeve as a coherent, integrated structure which is so important in conveying to the yarn some of its characteristic features.
  • Particularly suitable rotating bodies are those which have a configuration described by a straight line generator. Examples include bodies which are conical or frustoconical or essentially cylindrical in shape. In the context of cylindrically shaped bodies We mention that there has been used with conspicuous success a body'of cylindrical form which tapers ever so slightly (an angle of about 5), toward the direction in which the sleeve is moved 01f it.
  • Bodies of an essentially hemispherical or parabolic shape may also be employed in the process of this invention.
  • the body may be constructed of metal, plastics ceramic or any other suitable material. Conveniently, the body is provided with an integral shaft for connection to a suit-' able drive means.'
  • the application of tension to the filament by the rotating body attenuates it in the distance between the spinneret face and the point where the filament is substantially completely solidified.
  • the filament is accelerated as it passes to the body. Accordingly, the spinning speed of the filament, which is the speed of the filament at a point after solidification is substantially complete and attenuation with a reduction in denier of the filament has well-nigh ceased, is directly dependent upon the peripheral speed of the rotating body.
  • the spinning speed of the filament can be controlled in a direct and effective manner.
  • Filaments of certain polymeric materials are macromolecularly oriented as well as attenuated and accelerated by the rotating body.
  • the degree of orientation developed in the freshly spun filaments is related to the peripheral rotational speed in the sense that the greater the speed, up to a certain variable limit, the more effective the orientation. Consequently, when synthetic organic polymeric materials are utilised in this invention, spinning and drawing can be accomplished in a single operation and the yarn formed from the sleeve withdrawn from the rotating body will contain drawn continuous filaments.
  • peripheral speeds of less than 7,000 feet per minute are generally associated witth yarns of somewhat inferior properties to those which are obtained using bodies with a higher speed, and the spinning speed of the filaments is correspondingly low thereby resulting in a generally poor productivity.
  • the traverse mechanism there may be employed any device capable of imparting to the travelling filament a reciprocating, to-and-fro motion in a manner which speeds the filament along the length of the rotating body in a series of superimposed and interconnected helices.
  • Particularly suitable traverse mechanism are those wherein the filament passes through a thread guide contained in a traverse bar to which a reciprocating movement is imparted by mechanical, hydraulic, electromagnetic or other suitable means.
  • the desirably high peripheral speeds for the rotating body impose a lower limit on the traverse speed consistent with the satisfactory operation of the process and the formation of a yarn with good properties.
  • This lower limit for the traverse speed varies over a wide range independence upon a number of variable factors including the peripheral speed of the rotating body. It is preferred to use traverse speeds which are high relative to those normally employed in the winding of continuous filaments into packages in a continuous filament spinning machine. In the latter role, the traverse speed does not ordinarily exceed much above 500 cycles per minute.
  • the traverse speeds which in this invention are conducive to the smooth operation of the process and the formation of a yarn with maximum utility are generally over 600 cycles per minute and preferably over 1000 cycles per minute, when the traverse mechanisms are used in conjunction with rotating bodies having peripheral speeds between 7,000 and 20,000 feet per minute.
  • FIGURE 1 shows a schematic representation of an apparatus assembly useful in practicing the invention
  • FIGURES 2-4 show perspective views of differently shaped bodies which may be used as the rotatable body in the apparatus of FIGURE 1;
  • FIGURE 5 shows in plan view one traverse mechanism which may be used in the apparatus of FIGURE 1;
  • FIGURE 6 shows an alternative traverse mechanism which may be used in the apparatus of FIGURE 1;
  • FIGURE 7 is a diagrammatic representation of the configuration adopted by a filament when wrapped as a layer around the rotatable body
  • FIGURE 8 is a developed plan of the configuration shown in FIGURE 7;
  • FIGURES 9-10 are diagrammatic and essentially idealised views which illustrate the structure of the sleeve which is built up around the rotatable body and the relationship between various layer therein both on the body and as the sleeve moves off it in a direction along the axis of rotation;
  • FIGURE 11 is a diagrammatic view illustrating in more detail, and in a somewhat idealised manner, the relationship between two layers of the sleeve in the region where the sleeve is moving off the rotatable body;
  • FIGURE 12 is a diagrammatic view at a greatly enlarged scale of a section of the strand of loops devised from the sleeve after it has moved off the rotatable body and it illustrates the relationship between the various loops of which it is comprised and the structure of the individual loops;
  • FIGURE 13 is a diagrammatic view similar to that shown in FIGURE 11 but illustrating how the layers comprising the sleeve may be modified under the operating conditions and probably more closely approximates to the structure which is most frequently present in the sleeve.
  • FIGURE 14 is a diagrammatic view of a length of a strand of loops which is itself derived from a sleeve wherein the layers are modified as shown in FIGURE 13;
  • FIGURE 15 is a photograph of a model of a length of yarn made in accordance with this invention as it was observed under an ordinary microscope.
  • FIGURES 16-18 are photomicrographs at a magnification of X10, of length of yarn made in accordance with the procedure set forth in various examples hereinafter;
  • a freshly formed continuous filament indicated by reference numeral 20 is extruded through an orifice (not shown) in a spinneret 21 into room temperature air.
  • the extruded filament aftercooling and solidifying in the course of its downward passage through the air is wrapped around the continuous surface of a body 23 which is in the form of a truncated cone.
  • the body 23 contains an integral shaft 24 which is connected to a suitable drive mechanism (not shown) by means of which the body is rotated.
  • the peripheral speed i.e.
  • a godet surface speed of the rotating body, which will hereinafter for convenience be referred to as a godet, is sufiiciently high for the purpose of applying tension to the filament and thereby to attenuate it during its'passage between the spinneret and the godet.
  • the continuous filament during its downward travel is passed through the thread guid (not shown) of a traverse mechanism, generally indicated by reference numeral 25, which is located a short distance above the godet surface.
  • the traverse mechanism imparts to the travelling filament a reciproeating, to-and-fro movement in a plan normal to the means direction of filament travel and parallel to the longitudinal axis of the godet 23.
  • the filament is wound back and forth across the surface of the godet, from the skirt to the hose thereof, as a series of interconnected helices, which accumulate thereon in the form of a tapered tubular sleeve 26.
  • the ceramic guide ring 28 through which the strand 27 is passed constitutes such a twist barrier and it is observed that in most instances the twist is almost entirely imparted prior to the passage of the strand therethrough.
  • the yarn 29 so obtained is wound up as a tapered end package on a conventional wind-up arrangement using a traverse mechanism (not shown). As illustrated, the yarn is laid on a bobbin 30 surface driven by roller 31 to form a yarn package 32.
  • the speed of the yarn take up bobbin which effectively controls the rate at which the sleeve is pulled off the godet 23, is always much less than the rotational speed of the godet. Its speed is always maintained constant during a given operation and it is coordinated with the rotational speed of the godet, in accordance with requirements, for instance, twist level, for the yarn.
  • the godet around which the filament is wrapped as a sleeve and which applies tension to the filament thereby continuously pulling it down onto itself at a speed which is faster than the extrusion speed, is usually profiled so as to slope downwards in the direction along which the sleeve is withdrawn for then its orderly removal as a coherent, integrated structure is facilitated.
  • FIGURES 2-4 show perspective representations of actual godets that have been successfully used in this invention in the apparatus shown in FIGURE 1.
  • Each of the godets is a hollow lightweight construction with a continuous surface and is made of a high tensile strength aluminium alloy.
  • the shaft which is integral with the godet serves to attach it to a suitable drive, conveniently an electric motor, by means of which it is rotated.
  • the frusto-conical godet of FIGURE 2 has the following dimensions:
  • the bullet-nose godet of FIGURE 3 has the following dimensions:
  • the godet In terms of distance from the spinneret the godet should be located beyond the point where the downwardly travelling filament has substantially completely solidified otherwise the disruption of the filament into discontinuous staple length fibres may occur when the filament contacts the godet and when more filaments than one are being pulled down onto the godet fusion between adjacent filaments may result because of inadequate quenching time.
  • filaments derived from melt-spun polymers for instances, synthetic organic polymers such as polyamides, polyesters, polyhydrocarbons, polycarbonates and the like, the godet should be located beyond the region along the length of the extruded filament wherein the solidifying filament is in a highly transitional polyester state between the liquid and the solid states.
  • Attenuation of the filament is effected predominantly in this region for the stress imposed by the godet carries back along the filament and localises the attenuation in that region. In this transitional region the filament can be seen to accelerate and become taut, moving along its length at high speeds.
  • the optimism location for the godet is determined by simple experiments which involve altering its position until it attenuates the filaments Well but does not disrupt the filaments or cause them to fuse together.
  • the godet may be positioned anywhere between 18 inches and feet beneath the spinneret orifices.
  • the peripheral speed of the godet should be sufficiently high to macromolecularly orient the filaments as Well as to attenuate them.
  • the peripheral speed required to attenuate and orient the filaments to the desired extent which speed is related to the design characteristics of the godet, its dimensions and speed of rotation, will vary according to the polymer being spun and process conditions such as emergent viscosity of the polymer i.e. the melt viscosity at the time of extrusion, the rate of the extrusion and the linear distance between the spinneret face and the godet.
  • polyhexamethylene adipamide polyethylene terephthalate and polypropylene filaments a reasonable degree of macromolecular orientation, as evinced by birefringence measurements and properties such as tenacity can be attained at peripheral speeds over 7,000 feet per minute. Peripheral speeds of below 7,000 feet per minute result in low tenacity filaments of limited utility. The tenacity of filaments can be improved by stretching the yarns containing them but since this involves the addition of a further process step it is preferred to employ higher peripheral speeds and collect drawn filaments into the yarn. Above 7,000 feet per minute, the peripheral speed can be increased until excessive filament breakage occurs. The maximum peripheral speed which can be utilised without excessive filament breakage is primarily set by the extrusion rate. When excessive filament breakage at the spinneret occurs at a particular peripheral speed, then this can be minimised and the peripheral speed rendered practicable by using higher extrusion rates.
  • peripheral. speed of the godet is determined by its dimension, in particularits diameter in the region where the filament is lead around the godet and its rotational speed, a given peripheral speed can be attained either by rotating a relatively small godet at a comparatively high speed or by rotating at a slower speed a larger body.
  • a rotational speed of 20,000 revolutions per minute its peripheral speed at the skirt where its diameter is 2 inchesis approximately 15,000 feet per minute.
  • An equivalent peripheral speed could be obtained by using a godet of a similar cylindrical shape, but having a diameter of 6 inches by rotating it at 9,500 revolutions per minute.
  • the upper limit on the godet dimensions compatible with the orderly and progressive removal of the sleeve and the formation of the most satisfactory yarn depends upon factors such as the godet profile, the rotational speed and the traverse speed, but with godets of a large diameter there is an increasing propensity for snatching of the sleeve during its withdrawal; snatching results in the formation of a slub yarn of an irregular denier and consequently of limited utility and also the frequent breaking of filaments with the interruption of the process.
  • the downwardly travelling filament is lead through a traverse mechanism which imparts a reciprocating motion to the filament so as to spread it out over the surface of the godet in the form of a sleeve comprising a series of interconnected and superimposed helices, the traverse mechanism is located a short distance above the godet. If it is positioned too far away from the godet then there is some loss in the effectiveness of the traverse device in spreading the filament over the surface thereof, while, if it is too close to the godet then difliculties may 'be encountered in stringingup the apparatus.
  • the optimum location for the traverse mechanism is determined by shifting it away from the godet until the stringing-up of the apparatus can be effected without difiiculty.
  • this optimum distance is between 1 and 6 inches above the godet, and most commonly 1.5 to 4 inches above it.
  • the traverse mechanism should have a traverse speed which is high relative to the traverse speeds ordinarily employed in the winding of continuous filaments into packages in a continuous filament spinning machine.
  • the traverse mechanism comprises a thin metal traverse bar 33, one end 34 of which is clamped to an end of a U-shaped iron block 35 and the other end 36 carries a light two-pronged filament guide 37 constructed of two bi inch diameter and /2 inch long ceramic pins.
  • the iron block 35 serves as the core of an electromagnet, indicated generally by reference numeral 38, and the nexus 39 thereof is surrounded by a wire wound into a coil 40 which is connected through a variable transformer to a source (neither of which are shown) delivering 50 cycles of alternating current per second.
  • a silicon diode rectifier 41 is connected in series with the coil of the electromagnet so as to pass only alternate half cycles of current.
  • the flux induced in the iron core 35 imparts a reciprocating motion to the cantilever traverse bar 33 which is tuned to move back and forward at the desired speed of 50 cycles per second by adjustment of its free length.
  • the traverse is sinusoidal in character with an amplitude (peak-peak) of approximately 1.5 inches.
  • FIGURE 6 shows an alternative high speed traverse mechanism, which is mechanical rather than electrical in operation, and which may be used in the apparatus of FIGURE 1.
  • this traverse mechanism comprises an arrangement for converting the rotary motion of a crank into rectilinear movement, the latter operating on a traverse bar via a connecting rod, and its utilises a Scotch yoke to eliminate the irregularity of motion, common to all ordinary crank devices.
  • the filament being passed to the godet is carried through a ceramic thread guide 42 attached to one end of a light tubular steel traverse bar 43 which is pivotally connected at its other end to a bracket 44.
  • the traverse bar is also secured to a connecting rod 45 by a pin 46 which can move in a longitudinal slot 47 in the traverse bar.
  • the connecting rod is rigidly secured to a cross-head 48, which contains a slot 49 within which there is located a slidable block 50.
  • the block is connected through a crank pin 51 to a crank 52 attached to one end of an axle 53 which is rotated at a uniform speed by an electric motor controlled by a variac transformer (neither of which are shown).
  • a continuous reciprocating motion is transmitted through the connecting rod to the traverse bar which in moving back and forth describes an arc.
  • this traverse mechanism is reliable in operation and is capable of attaining traverse speeds of up to about 100 cycles per second.
  • the traverse is essentially sinusoidal in character and its speed can readily be altered and the amplitude adjusted, the
  • the traverse bar in the mechanisms shown in FIGURES 5 and 6 is positioned in a horizontal plane essentially at right angles to the long axis of the godet so that the filament passing through the thread guide is traversed back and forth along the length of the godet.
  • Traverse mechanism other than the two shown may be employed and it is not necessary that the reciprocating movement be imparted to the filament by its passage through a thread guide contained in a displaceable traverse bar.
  • the traverse mechanism may be pnuematic in operation with the filament passing through a device wherein it is subjected to a transverse stream of air the direction of which is rapidly and continuously alternated.
  • a similar effect may be obtained electrostatically by passing the filament between two plates the polarity of which is rapidly and continuously reversed.
  • the filament Due to the axial movement imparted to the filament by the traverse mechanism, and also the rotary movement of the godet, the filament is wrapped around the godet in a series of interconnected and superimposed helices which form an approximately tubular sleeve around the godet.
  • FIGURE 7 is a diagrammatic representation of the configuration adopted by a filament wrapped around the godet in one complete traverse cycle.
  • the filament advances along the godet in one direction as a righthand helix 54.
  • a second helix 55 in this instance a left-hand helix, which overlies the first helix, is formed.
  • Both helices contain the same number of turns and are of the same length which approximately corresponds to the traverse amplitude.
  • the structure derived from a single complete traverse comprises the two interconnected and superimposed helices, 54 and 55 of opposite hand, although generated in the same rotational direction.
  • This double helical structure constitutes one layer of the sleeve which is built up on the godet and for convenience in this specification the term layer will be used in reference to the double helical structure formed from one complete traverse.
  • a layer when projected onto a plane surface, as in the developed plan shown in FIGURE 8, describes a series of linked curves, the configuration of which is similar to certain kinds of lissajou figures known in mathematics.
  • the configuration of the filament within a layer is reflected in the structure of the axially-extending segments in the yarn as will be explained in more detail hereinafter.
  • the characteristic structure of the yarn of this invention and the properties manifest by it, are dependent upon the formation on the godet of a transient assembly in the form of a sleeve constructed of a plurality of layers each derived from a single traverse, and the orderly and progressive withdrawal of the sleeve from the godet.
  • the helical angle within the layer is determined by the peripheral speed of the godet, the godet profile and the traverse speed at which the traverse mechanism operates, and a high traverse speed is reflected in a relatively large helical angle.
  • a high value for the helical angle enhances the-frictional interconnection between successive layers and between the two helices of the same layer and aligns the terms of the helix into positions more suitable for withdrawal.
  • the minimum traverse speed compatible with the formation of a satisfactory yarn and the smooth operation of the process depends on the design characteristic of the godet, its dimensions, its peripheral speed, the speed at which the sleeve is withdrawn from the godet and like variable factors.
  • the traverse mechanism of FIGURES 5 and 6 when used with the godets shown in FIGURES 2-4 and other godets of similar dimensions operating at peripheral speeds of between 7,000 and 20,- 000 feet per minute, and with the sleeve being with:
  • the traverse speed can be varied over a wide range above 600 cycles per minute, preferably above 1,000 cycles per minute. Traverse speeds below 600 cycles per minute are as sociated with frequent breakdowns in the process and result in a slubbed yarn of irregular denier and conse: quently of limited utility. With peripheral speeds of less than 7,000 feet per minute, the traverse speed can be correspondingly less than 600 cycles per minute and still produce a reasonably uniform yarn of good properties.
  • the sleeve is essentially a transient assembly, for although its is continuously propagated by the deposition of additional layers around its outer surface it is continuously and simultaeously diminished by the withdrawal of layers from the interior thereof.
  • FIGURES 9 and 10 show in a diagrammatc and idealised manner, the relationship between successive linked layers on the godet and they illustrate phenomena which occur during the removal of the sleeve from the godet and its collapse into a strand of loops.
  • a newly deposited layer 56 overlaps the layer 57 deposited immediately previously but which, in the interval of the time after its formation, has moved down the inclined surface of the godet under the tractive effect exerted by layer 58 which has moved completely off the godet surface.
  • th sleeve In the cross-sectional view shown in FIGURE 9 th sleeve, of which only two layers are depicted, is a tegulated structure with the interconnected layers arranged on top of one another but with astaggered relationship between layers. As each layer comprises two interconnected and overlaid helices which are generated around the godet Serving as a framework, the actual structure of the sleeve more closely resembles that shown in the side view of FIGURE 10 with each layer contained for a variable part of its length within the layer assembled immediately after it and to which it is linked.
  • layer 57 is contained for part of its length within layer 56, the ,two layers being linked through the continuation ofa component helix of layer 57 as one of the helices, of opposite hand, in the layer 56.
  • An arrangement such asthat shown in FIGURES 9 and 10 makes for goodfrictional interaction between the overlaid layers and this assists-the removal of --the sleeve as an integrated structure with a retention of staggered .relationships between successivelayers.v Y r
  • FIGURE 11 illustrates the structure of the layers assembled around the godet, the relationship between two layers and the collapse of one of them as it moves off the godet and its elongation into a loop which constitutes an axially-extendingsegment in the resulting yarn.
  • a newlydeposited layer 60 comprises two helices 61 and 62, spread out over the length of the godet with the left-hand helix 62 overlying the right-hand helix 61 and the helices serially connected at the extreme left-hand end of the godet through the common chord 63 which constitutes the trailing end of layer 60.
  • Each of the helices contains five turns and two turns 64 and 65 at the forward'end of the first laid helix 61 have moved off the godet under the influence of the tractive effect, exerted by the layer 67 deposited on the godet immediately previously tothe layer 60.
  • the layer 60 is connected at its leading end 66 to the layer 67.
  • the layer 67 which likewise comprises two serially connected, five turn helices has, except for the trailing end, entirely moved off the godet surface.
  • the layer 67 collapses in the vertical direction and is elongated in the longitudinal direction thereby forming a long loop with interlaced limbs owing to the intercrossing of the limbs which occurs at the five nodal points (01-8) and which correspond to the points in the initial layer, where one helix crossed over the other.
  • FIGURES 9-11 are diagrammatic and somewhat idealistic for, in actual operation, the sleeve built' up on the godet normally contains many more layers, and having regardto their number, the fineness of the filaments and the speeds involved, it is impossible to determine with complete accuracy or to record-the structure of the sleeve, and the complex series of events which occur during its withdrawal.
  • -FIGURE 12 shows a diagrammatic view, at an enlarged scale of a small section of a strand of loops derived from a sleeve containing layers similar to the two layers shown with reference to FIGURE 11.
  • One loop 68 has its closed end 69 at the extreme lefthand end of the section and extends along t to terminate in its leading end 70.
  • One limb 71 of the oop because it derives from an underlying helix in the initial layer extends slightly further forward than the other limb 72 of the loop.
  • the two limbs of the loop are interlaced owing to the crossing of limbs which occurs at the five nodal points (a-e). This interlacing interlocks the limbs and so stabilises the loops, and is attributed tothe formation of the loop from a layer which comprises two serially connected overlaid helices of opposite hand.
  • the number of nodal points present corresponds to the number of turns within each helix of the layer.
  • the loop 68 is contained within another axially-extending loop 73 derived from the next succeeding layer within the sleeve and the two loops are interconnected at the leading end 74 of the loop 68.
  • the limbs of the loop 73 are interlaced in a similar manner to those for the loop 68.
  • loop 68 itself envelops another loop 75, the closed end 76 of which lies approximately midway along loops 68.
  • This loop also contains within it another loop 77, part only of which is shown.
  • the general picture is that of a nest of axiallyextending interconnected loops which have a complex structure. Loops within the strand are rarely so uniformly arranged as the diagrammatic illustration of FIGURE 12 suggests, but despite a certain degreeiof dislocation and derangement for reason which will be outlined hereinafter, the configurations adopted by the loops as shown in-FIGURE 12 occur with sufiicient constancy to provide cross-sections taken at random intervals along the length with approximately the same number of filaments.
  • the number of filaments in the cross-section corresponds to the peripheral speed of the godet and the lower speed at which the sleeve is withdrawn therefrom multiplied by the number of filaments passed to the godet. For example, if the peripheral speed of the godet is 10,000 f.p.m. and the sleeve withdrawn therefrom at a linear speed of 250 f.p.m., there will be, assuming one filament was passed to the godet, 10,000/250 or approximately 40 filaments at any point along the strand.
  • Some loops of the strand may not be confined to the distinct array formed by the nest of interconnected loops but may escape therefrom for the greater part of their length to be located around the nest in a more or less random manner, although they frequently are Wrapped loosely around it for a number of helical turns.
  • the structure of the strand of loops is always modified by the presence, in addition to the nest of interconnected loops and any long loops which may have escaped therefrom of a variable number of generally shorter-length loops which emerge from the axiallyextending loops, and extend outwardly therefrom.
  • pedicled bights Any loops which emerge out of the nest of interconnected loops in both the strand of loops and in the yarn derived therefrom will be referred to herein as pedicled bights to distinguish them from the axially-extending loops within the nest.
  • the pedicled bights thus comprise any loops which may have escaped from the definite arrangement of interconnected, axially-extending loops and loops which result from the displacement of helical turns in a layer within the sleeve while it is on the godet.
  • Pedicled bights comprising the latter kind of loop are often of shorter length than the others, but when both are present in the strand or yarn they are generally indistinguishable.
  • the shorter-length predicled bights are formed primarily in the sleeve built up around the godet, when the centrifugal force arising from the rotation thereof tends to throw loosely-wrapped individual turns of helices Outwards from the godet surface.
  • the effect which the centrifugal force may have on individual layers of the sleeve with the formation of variously sized but generally shortlength loops which provide pedicled bights in the strand of loops is illustrated in the diagrammatic and idealised FIGURE 13 which, apart from the modification with the layers arising from the centrifugal force, corresponds to FIGURE 11.
  • pedicled bights are always present in both the strand of loops and the yarn derived from it, but their actual number may vary enormously. Hence it is possible to produce a variety of structures, differing in the number of pedicled bights, which may 8 range from a relatively few to a multitude, and the arrangement of the pedicled bights around the nest of axially-extending loops.
  • FIGURE 14 is a diagrammatic view at a greatly enlarged scale of part of the strand of loops and the structure shown approximates more closely than the structure of FIGURE 12 to that commonly obtained in the operation of the process of this invention.
  • the strand comprises a central region 84 which consists of a nest of interconnected, axially-extending loops which, since they correspond to those shown in the strand of FIGURE 12, have not been indicated in detail.
  • Pedicled bights 85 of the shorter-length kind emerge from the central region and extend outwardly therefrom while a longer-length pedicled bight is formed from the lengths 86 of along loop which is not confined in the arrangement of the central region but is wrapped for a number of turns around it.
  • the limbs of the loop are interlaced at nodel points, two of which are shown at 87 and 88.
  • twist is inserted therein and this twist condenses the strand of loops formed from the sleeve into a bulky yarn.
  • the twist insertion is a result of the rotation of the godet relative to the linear movement of the strand of loops and it arises because at some stage in their withdrawal from the godet, the layers within the sleeve are located partly on the godet and partly in the strand of loops which has moved away therefrom under the impetus imposed by the wind-up device. With one end restrained in the strand which it itself held by the wind-up device, the other end is rotated by the godet and conse- 15 quently twist is inserted in the strand. Thetwist inserted runs down the strand until it encounters a twist barrier.
  • the short length loops which are generally present and which project outwardly from the godet owing primarily to the action of the cenetrifugal force, may not 'be carried into the main strand of loops and hence they are twisted not at all or to a lesser degree than the axially-extending loops within the strand.
  • These short-length loops are present in the strand and the yarn as pedicled bights.
  • FIGURE 15 is a photograph of a model which actually reproduces the structure of a short length of yarn made in accordance with this invention as it was observed under a microscope. So numerous are the pedicled bights in this yarn that they form a discontinuous peripheral region 92 around a relatively more compact core 91.
  • the core comprises a concatenation of interconnected loops, each of which constitutes a segment, aligned essentially parallel to the long axis of the yarn but with the loops twisted together in more or less regular helices with a helical angle of around 70.
  • Cross-sections taken at random along the lengths of the yarn show an approximately constant number of filaments in the core.
  • the number of filaments found is related to the linear speed (E) at which the filaments meet the godet, their number (N) and the linear speed (W) at which the loops are withdrawn from the godet.
  • the number can be found by multiplying the ratio E XN
  • the cross-sections frequently show in addition to the parallel filaments which represent the limbs of the loop, the curved end of one or more loops.
  • the loops within the core are arranged so that the majority of the loops are contained for at least part of their length within another loop, and with a general advancement of the loops along the yarn.
  • the axial arrangement of the loops within the core is more complex than the above description thereof, and, in particular, there is considerable entanglement between adjacent loops which may distort the nest of interconnected loops, although overall the most arrangement is retained.
  • the overall general picture is that of a nest of interconnected loops, each containing a segment, aligned in a direction essentially parallel to the long axis, although helically twisted in that direction.
  • the various loops are stabilised by the interlacing of the component limbs.
  • the peripheral region 92 which constitutes a discontinuous shell around the core 91 comprises a multiplicity of pedicled bights which emerge from the relatively compact core and which extend outwardly therefrom in a more or less random array.
  • the yarn shown in FIGURE 15 has a structure which is representative of many years made in accordance with the invention. However, although pedicled bights are invariably present in the yarns of this invention, they need not be so numerous as in the structure shown in FIG- URE 15. In some yarns of this invention, there are not sufiicient pedicled bights present to form a distinct peripheral region, and the structure is composed essentially of a nest of interconnected axially-extending segments.
  • pedicled bights are always presentto a variable extent in the yarn when it is initially formed, they may subsequently be removed therefrom by, for example, cutting or singeing.
  • a practical process for removing pedicled bights from the as-formed yarn comprises bringing the yarn into close proximity to a red-hot wire.
  • the singeing treatment markedly reduces the number of pedicled bights and gives the yarn which consists essentially of a nest of axially-extending segments, each of which comprises a loop.
  • a characteristics feature of the yarn represented in FIGURE 15 as with all the yarns of this invention, is its bulkiness, i.e. relative volume occupied by a given weight and the irregular nature of its surface as a result of the presence of a peripheral shell containing a more or less random array of loops.
  • the bulkiness is a reflection not only of the readily visible loops arranged in a random array at the surface of the yarn, but also the structure of the core wherein loops which are of a complex structure and which are comparable to the staple fibres in a spun staple yarn nest one within another with some integrated entanglement between them. Because of their bulky nature, the yarns have an excellent covering power and fabrics made from them have good warmth. The irregular surface of the yarns gives them a handle or feel similar to that of spun yarn made of comparable staple length fibres.
  • the twist inserted in the strand of loops is a function of the rotary movemnt of the godet relative to the linear speed at which the bundle is moved away by the wind-up device it is determined by the operating condi-, tions at which the apparatus is employed.
  • the twist insertion rate is t.p.i. or 5 turns per inch.
  • optimum twist for best properties in the yarn is dependent upon the denier thereof and the relationship between these two parameters is concisely expressed by means of the twist factor. This is defined (see, for instance, Textiles Terms and Definitions, 4th edition, published by the Textile Institute, Manchester,) as the actual twist divided by the square root of the cotton count and the cotton count is related to the denier.
  • the most satisfactory yarns of this invention have a twist factor in the range between and 10 and most usually between 1 and 4.
  • the direction of the twist which is inserted depends upon the direction in which the godet is rotated.
  • the yarn may be drafted down to lower deniers by conventional means.
  • the apparatus described with reference to FIGURE 1 is, from a technical standpoint, a false twist apparatus, since neither the spinneret nor the package on which the yarn is wound up rotate about the yarn axis, yet the yarn which is wound must be considered as possessing real twist. Certainly, it is virtually impossible to remove any appreciable amount of twist from the yarn by the application of tension thereto and the yarn is a stable product which can be wound up in a conventional package and stored indefinitely.
  • the bulk factor was determined in the following manner.
  • One of those filaments was passed through the filament guide in the sinusoidal traverse mechanism shown in FIG- URE 5 which operated at a frequency of 50 cycles per second and had an amplitude of 1.5 inches and then wound around the frusto-conical shaped godet having the same dimensions as the godet shown in FIGURE 2.
  • the godet which was driven by an electric motor at a speed of 18,000 rpm. which gave a peripheral speed of 9,200 f.p.m., was located 26 inches below the spinneret face and 2 inches below the traverse mechanism.
  • the filament was wrapped around the godet in the form of a succession of layers each of which, in this particular example, had the form illustrated in FIGURE 7, namely two serially connected helices, laid in opposite directions over a length of 1 /2 inches of the godet surface with one overlapping the other. Each helix contained 3 turns of the filament so that 6 turns were laid for a complete traverse.
  • the diameter of the resulting tapered tubular sleeve 15 was 2.5 inches at its widest part and 1.4 inches at its narrowest.
  • the sleeve was continuously pulled off the godetalong the longitudinal axes thereof, when it extended and subsequently collapsed into a strand of loops which was twisted into a yarn 19, in which form it was wound up at a rate of 110 f.p.m. via a stationary guide placed on the axis of the godet and one inch away from its nose.
  • the sleeve was pulled off the godet without the assistance of mechanical means other than the wind-up.
  • the yarn which possessed 13 t.p.i. had the following properties:
  • Denier 1 Breaking strength gm 160 Extensibility percent 30 Individual filaments in the yarn were present as loops which had a length varying up to 18 inches and had a birefringence of 0.036 and a denier of 1.4.
  • EXAMPLE 2 Polyhexamethylene adipamide having an inherent viscosity of 0.882 (measured in percent phenol/water at 25 C. and a concentration of 0.5 percent) and containing 0.03 percent titanium dioxide was extruded through 0.009 inch diameter orifices in a spinneret at a rate of 0.05 lb. per hour per orifice at a spinning temperature measured at the spinneret of 273 C. into ambient air at 20 C.
  • One of the polyhexamethylene adipamide filaments was passed along a generally defined downward path to a godet positioned slightly off set from the spinneret and at a distance of 38 inches from its face.
  • the godet was profiled so as to resemble the bullet-nose shaped godet shown in FIGURE 3 and it had the following dimensions.
  • the godet was attached through its stem to an electric motor by means of which it was driven at 18,000 r.p.m. when its periphenal speed was 9,400 f.p.m.
  • the filament was lead through the thread guide in the traverse bar of the traverse mechanism shown in FIGURE 6 with the traverse bar lying in a horizontal plane normal to a vertical plane through the longitudinal axis of the godet.
  • the traverse mechanism was located 2 inches above the surface of the godet and operated at a traverse frequency of 2,000 cycles per minute and an amplitude of 1.5 inches.
  • the jet was then moved down to a position below the godet rotating at its operating speed and the filament carried down by the jet was lead through the thread guide in the traverse bar which was at rest.
  • the filament was then wrapped manually around the godet surface which caused the filament to break above the aspirator jet, and the traverse mechanism was simultaneously set in motion. Thereafter, the godet pulled the filament down upon itself and because of the action of the traverse mechanism an approximately tubular shaped sleeve was propagated around the godet.
  • the circumference of the sleeve at its narrow end was pulled away through a ceramic guide eye to a constant speed wind-up device.
  • the wind-up device which operated at 20 f.p.m. imparted a substantially constant tension to the sleeve and consequently an equilibrium was soon attained between the formation of the sleeve on the godet and its withdrawal in the form of a strand of loops.
  • the photomicrograph shows that the yarn conin which form it was wound up at a rate of 120 f.p.m. tains relative few pedicled bights.
  • the yarn so obtained had the following properties.
  • EXAMPLE 3 The apparatus of Example 2 except for the replacement The yam had the handle and feel of a spun yarn made of the spinneret by a screw extruder was employed in the from polyhexamethylene iadipamide staple fibres, and it Preparatlon 0f Y mposed of polypropylene filacould be Woven into a fabric possessing a good warmth ments. The pertlnent dimensions and distances are the same as in that example.
  • EXAMPLE 4 Polypropylene having an inherent viscosity of 1.40 A photomicrograph of a length f the yarn is shown (measured in decalin at 135 C.
  • the pedicled bights one of the Polypropylene filaments p in this y could b reduced i number by Singeing, or by passing was lead through the traverse mechanism onto the godet. it over a red hot wire, or by cutting, as they would b
  • the operating conditions for the traverse device and the wrapped more tightly around the core by passing the godet Werfi the Same as in Example yarn through an ir o t The sleeve formed on the godet was continuously pulled up away therefrom along the axis of rotation and the yarn EXAMPLE 5 which formed was wound up at a speed of 70 f.p.m.
  • the yarn of this example had a bulk, as expressed by The Yarn had the followmg Properties s t zpllv g talfrgct r, comparable to that of an equivalent spun DeI-fier T 762 6O Tw st (t.p.1.) 21.4 EXAMPLE 6 Twlst factor 33g Tenacity (gms./denier) 0.48 A photomicrograph of a length of the yarn is shown Extensibility (percent) 124.5 in FIGURE 18. Once again there are numerous pedicled Bulk factor (percent) 9.4 bights 99 arranged around a core 97.
  • the pedicled bights i l appear to be more randomly arranged than those in the Individual filament 1n the yarn had a denler of 5.7 and yarn of Example 4 although some of them, for instance a blrefnngence of 0023' those indicated by reference numeral 98 are loosely
  • the yam had the handle and feel of a Yarn spun from Wrapped f r a n b f m p ypropylene staple fibres and 1t had a greater bulk than a comparable staple fibre yarn.
  • EXAMPLE 7 The apparatus of Example 2 was employed in the preparation of yarns composed of polyethylene terephthalate filaments. The pertinent dimensions and distance e e e same as in tha exam l
  • EXAMPLE 9 The procedure of the previous example was repeated except that two' polypropylene filaments instead of one wee passed through the traverse mechanism onto the g0 ct,
  • suitable filaments are prepared from fibreforming polyamides such as polyhexamethylene adipamide, polyepsilon caprolactam and poly-omega-aminoundecanoic acid, polyesters, such as polyethylene terephthalate, cellulosics, such as cellulose acetate or triacetate,
  • polyacrylics vinyl polymers, vinylidene polymers, polyurethanes, polyhydrocarbons, and so on.
  • Composite filaments, and filaments derived from blends of polymeric materials may also be used.
  • filaments having a normal cross-section such as those produced where a spinneret having circular shaped orifices is employed for the spinning thereof
  • filaments having a non-circular cross-section are also suitable, for instance the trilobal shaped polyhexamethylene adipamide filaments of Example 10, and may impart desirable effects to fabrics derived therefrom.
  • An acceptable yarn with good bulk characteristics can be derived from a single filament although many more filaments, generally not more than 50, can also be employed.
  • the bulky yarns, and the fabrics into which such yarns are made up will tend to have those properties, notably handle or feel, covering power and warmth, normally associated with spun staple yarn structures.
  • the properties inherent in the material forming the continuous filaments will be present, for example, the hard wearing, good strength and no-rotting characteristics associated for example with polyamide yarns and fabrics.
  • the yarns can readily be handled by conventional textile machinery and have been Woven and knitted into useful fabrics.
  • the bulky yarn is simply and economically prepared by a process which only requires extremely simple equipment and which is fully integrated with the spinning of the continuous filaments from a source material.
  • EXAMPLE 13 A polyhexamethylene adipamide filament made in the manner set forth in Example 2 was processed into a yarn using the apparatus assembly of that example. The godet was rotated at a constant speed of 18,000 rpm. and the sleeve formed therein withdrawn along the axis of rotation and wound up as a yarn at a speed of 80 f.p.m.
  • a relatively tension resistant bulky continuous filament yarn which possesses a locked loop structure and which comprises a relatively compact core and a less compact peripheral region, the core being formed of essentially axially-extending segments which progressively advance along the axis and which are arranged so that a majority of the segments are contained for at least part of their length within another segment, said segments being twisted together, and the peripheral region being formed of a multiplicity of predicled bights which emerge from the core and extend outwardly therefrom.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
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US3969885A (en) * 1973-12-06 1976-07-20 Toyo Boseki Kk Method for manufacturing a textured yarn

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CH608250A5 (da) * 1976-06-15 1978-12-29 Mettler S Fr Soehne Ag Maschin
DE2823532C2 (de) * 1978-05-30 1983-08-04 Franz Fourne Vorrichtung zur Herstellung von gekräuselten, synthetischen Spinnfäden mit einem Wickelkörper
US4617789A (en) * 1985-04-01 1986-10-21 The United States Of America As Represented By The United States Department Of Energy Apparatus and method for fabricating multi-strand superconducting cable
US7500345B2 (en) * 2006-11-07 2009-03-10 The Goodyear Tire & Rubber Company Mandrel for a tubular strander
WO2019143132A2 (ko) * 2018-01-16 2019-07-25 주식회사 와이지켐 킨키 텍스처 및 나선형 회전 꼬임으로 경사 길이 특성이 구현된 필라멘트들의 연속 스트랜드 및 이의 제조방법

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US2886877A (en) * 1954-08-30 1959-05-19 Owens Corning Fiberglass Corp Method and apparatus for producing staple like yarn from continuous strand
US3060674A (en) * 1957-12-19 1962-10-30 Owens Corning Fiberglass Corp Method for producing glass roving
US3118213A (en) * 1961-05-03 1964-01-21 Owens Corning Fiberglass Corp Spun roving apparatus

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US2369481A (en) * 1938-03-22 1945-02-13 Owens Corning Fiberglass Corp Manufacture of spun glass fibers
FR53817E (fr) * 1944-07-05 1946-09-09 Saint Gobain Procédé et dispositifs pour la fabrication de rubans ou files de fibres de verre ou autres matières
US2854814A (en) * 1955-12-27 1958-10-07 Ind Rayon Corp Method and apparatus for the production of bulk yarn
US3217482A (en) * 1963-08-30 1965-11-16 Monsanto Co Apparatus for texturizing yarn

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US2231815A (en) * 1937-08-25 1941-02-11 Owens Corning Fiberglass Corp Fibrous article
US2886877A (en) * 1954-08-30 1959-05-19 Owens Corning Fiberglass Corp Method and apparatus for producing staple like yarn from continuous strand
US3060674A (en) * 1957-12-19 1962-10-30 Owens Corning Fiberglass Corp Method for producing glass roving
US3118213A (en) * 1961-05-03 1964-01-21 Owens Corning Fiberglass Corp Spun roving apparatus

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Publication number Priority date Publication date Assignee Title
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LU48803A1 (da) 1965-08-10
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US3492803A (en) 1970-02-03

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